Bulk transport system for dense products

ABSTRACT

A method for filling a container with a plurality of particles or a liquid includes a bulk packaging support structure for supporting the flexible container during filling. The support structure includes first and second foldable members each having a bottom portion and a first wall section that is pivotally connected to the bottom portion along a primary fold line. A second wall section is pivotally connected to the first wall section along a secondary fold line that extends perpendicular to the primary fold line. The first and second foldable members are releasibly engaged with one another such that the bottom portion of the first foldable member is disposed between the second wall section and the bottom portion of the second foldable member. The radially flexible container disposed within the support structure is filled through a large diameter to a fill level. The large diameter of the radially flexible container is then reduced to a smaller fill diameter in vertical relationship to the fill level as the fill level rises during filling of the flexible container.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/654,301 for a BULK TRANSPORT SYSTEM FOR DENSE PRODUCTS, filed on Feb. 18, 2005, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a packaging system for products and more particularly to a container formed from a pair of foldable members.

2. Description of the Related Art

Reusable containers for products that are shipped in bulk are usually very sturdy for at least two reasons. First, reusable bulk containers will often hold a large quantity of product. Also, reusable bulk containers must be amenable to return transit back to the point of origination without damage. Based on these operating conditions, reusable bulk containers will often be heavy, expensive and difficult to collect and store when not in use. Many empty bulk containers are damaged or lost during transit back to the point of origination.

SUMMARY OF THE INVENTION

The invention provides a method for filling a container with one of a plurality of particles and a liquid. The method includes the step of filling a radially flexible container through a large diameter with one of a plurality of particles and a liquid to a fill level. The method also includes the step of reducing the large diameter of the radially flexible container to a smaller fill diameter in vertical relationship to the fill level as the fill level rises during filling of the flexible container. The method also includes the step of placing a paperboard structure on opposing sides of the radially flexible container to support the radially flexible container during filling.

Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a foldable member according to the exemplary embodiment of the invention;

FIG. 2 is a perspective view of a first and second foldable members engaged with one another to form a reusable bulk container according to the exemplary embodiment of the invention;

FIG. 3 is a cross-sectional view taken along section lines 3-3 in FIG. 2; and

FIG. 4 is a cross-sectional view of a container formed according to one embodiment of the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now to FIG. 1, a foldable member 10 includes a first or bottom portion 12 and a second or side portion 14. A primary fold line 16 is disposed between the first and second portions 12, 14. The first portion 12 includes an upwardly facing surface 18. The second portion 14 includes an inwardly facing surface 20. When the first and second portions 12 and 14 are folded relative to one another along the fold line 16, the surfaces 18 and 20 are generally perpendicular and substantially facing one another, best shown in FIG. 2. In alternative embodiments of the invention, a foldable member could be formed with a single second portion (similar to first portion 14) and pair of first portions (similar to first portion 12) disposed on opposite sides of the single second portion.

The second portion 14 includes a plurality of secondary fold lines 22, 24, 26, 28. The second portion 14 is folded about the plurality of fold lines 22, 24, 26, 28 to define wall sections 30, 32, 34, 36, 38. The wall sections 30, 32, 34, 36, 38 form one-half of a reusable bulk container 40. One of the wall sections, a first wall section 34 in the exemplary embodiment of the invention, is pivotally connected to the bottom portion 12 along the primary fold line 16. A second wall section 32 is connected to the first wall section 34 along a secondary fold line 24. A third wall section 36 is connected to the first wall section 34 opposite the second wall section along a secondary fold line 26. A fourth wall section 30 is connected to the second wall section 32 opposite the first wall section 34 along a secondary fold line 22. The second portion 14 stands upright in the container 40 and the first portion 12 defines the bottom of the container 40.

Referring now to FIGS. 2 and 3, the container 40 includes the foldable member 10 and a second foldable member 10 a. The second foldable member 10 a is formed substantially similar as the first foldable member 10. For example, the second foldable member 10 a includes a first portion 12 a with an upwardly facing surface 18 a, a second fold line 16 a, and a second portion having wall sections such as wall section 34 a. The wall sections of the first and second foldable members 10, 10 a cooperate to form a frame-like structure for supporting a radially flexible container such as a bag (shown in phantom). Products in bulk can be moved to the bag. When the first and second foldable members 10, 10 a are engaged with respect to one another, the first portion 12 of the first foldable member 10 is disposed between the wall sections 30 a, 32 a, 36 a, 38 a and the first portion 12 a of the second foldable member 10 a. Also, an edge 42 of the first portion 12 contacts the second foldable member 10 a adjacent to the fold line 16 a. In alternative embodiments of the invention, a container such as container 40 could be formed from one foldable member or from more than two foldable members. An alternative container could be formed from the alternative foldable member having two first portions, such as described above. An alternative container could also be formed from more than two foldable members wherein adjacent foldable members are engaged with respect to one another with mating tabs and notches, tape, or any other type of connection structure known in the art.

After the first and second foldable members 10, 10 a have been engaged with respect to one another, a flexible container such as a bag can be positioned between the respective second portions 14, 14 a. In at least some embodiments of the invention, the first and second foldable members 10, 10 a, reduce the cost associated with filling the bag by eliminating the need for complex mechanical structure for holding the bag in place during filling. The bag can be filled with particulate material or liquids, such as syrups, fruit fillings, honey, oil, tar or cold patch. The bag (shown in phantom in FIG. 2) can be folded over the side sections 14, 14 a. For example, the opening of the bag can be extended around and supported by the wall sections 30, 32, 34, 36, 38, 30 a, 32 a, 34 a, 36 a, 38 a. The wall sections 30, 32, 34, 36, 38 are transverse to one another to correspond generally to a portion of the circumference of the bag. Likewise, the wall sections 30 a, 32 a, 34 a, 36 a, 38 a are similarly transverse to one another. The wall sections 30-30 a, 32-32 a, 34-34 a, 36-36 a, 38-38 a are mirrored with respect to each other to substantially encircle the bag. The bag can receive a quantity of product in bulk form. After the bag has been filled to the extent desired, the top of the bag can be drawn over one wall section and the container 40 wrapped in stretch wrap to maintain the bag in a closed orientation.

In another aspect of the exemplary embodiment of the invention, the container 40 and bag could be wrapped in accordance with the teachings of U.S. Pat. No. 6,494,324, which is incorporated by reference. The '324 patent discloses transportable container and a method for forming the container. The container 40 and bag can be wrapped during filling, the level of wrap following the fill level as the fill level rises during filling. Alternatively, the container and bag can be processed according to one or more of the disclosures of U.S. Pat. Nos. 6,892,768; 6,918,225; 6,935,385; and 6,945,015, as well as application Ser. No. 10/280,969, which are hereby incorporated by reference.

In another aspect of the exemplary embodiment of the invention, the wall sections 32, 36, 32 a, 36 a include punch-out portions 44, 46, 48, 50, respectively. The punch-out portions 44, 46, 48, 50 can be removed from the respective wall sections 32, 36, 32 a, 36 a and receive a handle from another container, such as a sack. The handles of the sack can extend through the openings defined when the punch-out portions 44, 46, 48, 50 are removed or folded out of alignment with the respective wall sections 32, 36, 32 a, 36 a. After the sack has been placed between the two second portions 14, 14 a, the sack and second portions 14, 14 a can be wrapped with stretch wrap. Alternatively, the punch out portions 44, 46, 48, 50 can remain at least partially connected to the side sections 14, 14 a and retain a bag in place prior to filling.

In another aspect of the exemplary embodiment of the invention, the first portion 12 defines first and second tab lines 52, 54 and tabs 56, 58. In operation, a handling device for handling the container 40 can engage one or both of the tabs 56, 58 to move the container 40.

The exemplary embodiment of the invention could also include a frame (not shown) to support the bag during filling. The frame could be relatively light weight and formed from relatively small diameter rod. The frame would be shaped to correspond to the interior of the container 40 and would be removable after the bag is filled and wrapped.

FIG. 4 shows an alternative embodiment of the invention. A bag 60 has been filled with a mass of material 62. The material 62 can be liquid or can be a plurality of discrete particles. Prior to filing, the bag 60 was placed on, and folded over, first and second foldable members lob, 10 c. The first and second foldable members 10 b, 10 c supported the bag 60 in a desired position during filling. The first and second foldable members 10 b, 10 c do not overlap one another, as was shown with respect to the bottom portions 12, 12 a, of the first and second foldable members 10, 10 a, in FIGS. 1-3. During filling, the bag 60 was wrapped with wrap 64 to reduce the diameter of the bag 60. The wrap 64 was applied substantially at the fill level of the bag 60 as the fill level rose. The first and second foldable members 10 b, 10 e were compressed with the bag 60 during wrapping.

The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims. 

1. A method for filling a container with one of a plurality of particles and a liquid comprising the steps of: filling a radially flexible container through a large diameter with one of a plurality of particles and a liquid to a fill level; reducing the large diameter of the radially flexible container to a smaller fill diameter in vertical relationship to the fill level as the fill level rises during filling of the flexible container; and placing a paperboard structure on opposing sides of the radially flexible container to support the radially flexible container during filling.
 2. The method of claim 1 wherein the placing step further comprises the steps of: positioning a first foldable member under and at least partially around the radially flexible container; and positioning a second foldable member shaped similar to the first foldable member under and at least partially around the radially flexible container.
 3. The method of claim 2 wherein the placing step further comprises the steps of: overlapping the first and second foldable members with respect to one another under the radially flexible container. 4-17. (canceled)
 18. A method for filling a container with one of a plurality of particles and a liquid comprising the steps of: forming a support structure with a first foldable member and a second foldable member that releasibly engages the first foldable member for supporting a radially flexible container; disposing the radially flexible container in the support structure; filling the radially flexible container through a large diameter with one of a plurality of particles and a liquid to a fill level; and reducing the large diameter of the radially flexible container to a smaller fill diameter in vertical relationship to the fill level as the fill level rises during filling of the flexible container.
 19. The method as set forth in claim 18 further including the step of forming the first and second foldable members with each of the first and second foldable members including a bottom portion having an upwardly facing surface and a side portion directly connected to the bottom portion along a primary fold line for substantially encircling the radially flexible container.
 20. The method as set forth in claim 19 wherein the each of the side portions of the first and second foldable members include a first wall section extending between a top and a bottom and further including the step of: disposing each of the first wall sections substantially perpendicular to the connected bottom portion along the primary fold line.
 21. The method as set forth in claim 20 further including the step of overlapping the bottom portions of the first and second foldable members with respect to one another, wherein the first wall section of the first foldable member and the first wall section of the second foldable member are spaced and parallel relative to one another for receiving a flexible container in the support structure.
 22. The method as set forth in claim 20 further including the steps of: directly connecting a second wall section that extends between a top and a bottom to each of the first wall sections of the first and second foldable members along a secondary fold line that extends between the top and bottom and perpendicular to the primary fold line, wherein each of the second wall sections is moveable about the secondary fold line for substantially encircling the radially flexible container; and spacing the upwardly facing surface of the second foldable member and the bottom of the second wall section of the second foldable member to define a gap for receiving the bottom portion of the first foldable member to form the support structure and wherein the bottom of the second wall section of the second foldable member is movable over the upwardly facing surface of the first foldable member for substantially encircling the radially flexible container.
 23. The method as set forth in claim 22 further including the steps of directly connecting a third wall section that extends between a top and a bottom to each of the first wall sections opposite the second wall sections of the first and second foldable members along a secondary fold line that extends between the top and bottom and perpendicular to the primary fold line, wherein each of the third wall sections is moveable about the secondary fold line for substantially encircling the radially flexible container; and spacing the upwardly facing surface of the second foldable member and the bottom of the third wall section of the second foldable member to define a gap for receiving the bottom portion of the first foldable member to form the support structure and wherein the bottom of the third wall section of the second foldable member is movable over the upwardly facing surface of the first foldable member for substantially encircling the radially flexible container.
 24. The method as set forth in claim 23 further including the steps of: directly connecting a fourth wall section that extends between a top and a bottom to each of the second wall section opposite the first wall sections of the first and second foldable members along a secondary fold line that extends between the top and bottom and perpendicular to the primary fold line, wherein each of the fourth wall sections is moveable about the secondary fold line for substantially encircling the radially flexible container; and spacing the upwardly facing surface of the second foldable member and the bottom of the fourth wall section of the second foldable member to define a gap for receiving the bottom portion of the first foldable member to form the support structure and wherein the bottom of the fourth wall section of the second foldable member is movable over the upwardly facing surface of the first foldable member for substantially encircling the radially flexible container.
 25. The method as set forth in claim 24 further including the steps of: directly connecting a fifth wall section that extends between a top and a bottom to each of the third wall section opposite the first wall sections of the first and second foldable members along a secondary fold line that extends between the top and bottom and perpendicular to the primary fold line, wherein each of the fifth wall sections is moveable about the secondary fold line for substantially encircling the radially flexible container; and spacing the upwardly facing surface of the second foldable member and the bottom of the fifth wall section of the second foldable member to define a gap for receiving the bottom portion of the first foldable member to form the support structure and wherein the bottom of the fifth wall section of the second foldable member is movable over the upwardly facing surface of the first foldable member for substantially encircling the radially flexible container.
 26. The method as set forth in claim 25 further including disposing punch-out portions in at least one of the first, second, third, fourth and fifth wall sections of the first and second foldable members for retaining the radially flexible container.
 27. The method as set forth in claim 19 further including the step of contacting the second foldable member adjacent the primary fold line of the second foldable member with an edge on the upwardly facing surface of the bottom portion of the first foldable member and disposed opposite the primary fold line of the first foldable member.
 28. The method as set forth in claim 19 further including the steps of: pivotally connecting first and second tabs to the bottom portion of one of the first and second foldable members along first and second tab lines; and extending the first and second tabs perpendicular to the bottom portion of the first and second foldable member to assist in the handling of the support structure.
 29. The bulk packaging support structure as set forth in claim 19 wherein the bottom and side portions of the first and second foldable members are generally rectangular.
 30. The method as set forth in claim 19 further including the step of overlapping the bottom portions of the first and second foldable members with respect to one another.
 31. The method as set forth in claim 18 wherein the first and second foldable members have a same shape.
 32. The method as set forth in claim 18 wherein the reducing the large diameter step is further defined as wrapping the radially flexible container with stretch wrap to reduce the large diameter of the radially flexible container to a smaller fill diameter in vertical relationship to the fill level as the fill level rises during filling of the flexible container.
 33. The method as set forth in claim 32 further including the step of wrapping the first and second foldable members with stretch wrap as the radially flexible container is wrapped with stretch wrap during filling of the flexible container. 